Hollow building module of corrugated polyurethane foam sections with elongated edge members



June 7, 1966 Filed May 7, 1962 E. E. HOYT, JR 3,254,464

HOLLOW BUILDING MODULE OF CORRUGATED POLYURETHANE FOAM SECTIONS WITH ELONGATED EDGE MEMBERS 5 Sheets-Sheet 1 INVENTOR 424 190/7; J1:

June 7, 1966 HQYT, JR 3,254,464

HOLLOW BUILDING MODULE OF CORRUGATED POLYURETHANE FOAM SECTIONS WITH ELONGATED EDGE MEMBERS Filed May 7, 1962 5 Sheets-Sheet 2 INVENTOR EflEL E. HQYZfz/r.

BY%MGL June 7, 1966 E E. HOYT, JR 3,254,464

E OF COR HOLLOW BUILDING MO RUGATED POLYURETHANE FOAM SECTIONS H ELONGATED EDGE MEMBERS Filed May '7, 1962 5 Sheets-Sheet 5 United States Patent Office 3,254,464 Patented June 7, 1966 The present invention relates to a structural building system which includes .a building panel module of novel construction and more particularly to a building system characterized by inclusion therein of lightweight insulative modular panels comprising rigid cellular plastic foam interiors and cover sheets of paper or the like;

In the present invention, the basic panel has been utilized in the development of a unique structural system of great adaptability and wide application, particularly in building wall and partition construction. In accordance with the present invention, means are furnished for constructing lightweight, insulative interior and exterior walls which may be either partition walls or load bearing walls, in a rapid and structurally sound manner.

Generally, the structural system according to the present invention comprehends a basic building panel or module comprising a first section and a second section, each of said sections being substantially identical in physical characteristics and each com-prising a plastic foam interior having a generally corrugated cross section and covering material bonded to each of two main surfaces thereof, I he first and second sections are adhesively fixed or bonded to each other along raised portions of the respective corrugations in a manner to define a multiplicity of hollow passages extending interiorly throughout the panel. The foam interior of each section of the panel is preferably a rigid polyurethane foam comprising a polyol and and organic polyisocyanate.

In combination wtih the basic'modular panel described above, the present invention comprehends a load bearing wall construction formed by inserting a multiplicity of vertical structural members, of material quality and number sufiieient to support a given load, each in one of the hollow spaces defined by the bonded first and second panel sections, and erecting wall sections so formed with the corrugations and the structural members so inserted, vertically disposed. In this manner the l/r characteristics of the vertical structural members are enhanced by the continuous bracing of the foam-cored sections of the panel and an increased load bearing strength inures, as persons skilled in the structural arts will appreciate.

Further in the present invention, there is a structural building wall system, according to which load bearing or partition walls may be constructed in a continuous manner with discrete modules joined to make a full wall. This combination comprehends adding to the basic panel described above, a cleated base plate, a cleated cap strip and vertically disposed spline assemblies to connect the panel modules together.

With the foregoing and other features in view, which shall hereinafter more fully appear, the present invention will now be described with reference to the appended drawings'wherein:

FIGURE 1 is an isometric assembly drawing of a typical exterior wall construction according to the present invention; I

FIGURE 2 is a cross-sectional detail showing one form of vertical spline assembly for connecting adjoining panel sections at a straight angle and illustrating the arrangement of a structural element in a wall hollow passage;

FIGURE 3 is a cross-sectional detail showing a form of vertical spline assembly for connecting adjoining panel sections at an obtuse angle;

FIGURE 4 is a cross-sectional detail showing a corner post vertical spline assembly for connecting-wall sections at a right angle and FIGURE 5 is an isometric assembly drawing showing an alternative form of vertical spline assembly for conneoting adjoining panel sections at a straight angle.

Referring to FIGURE 1, there is shown a basic panel module 11 comprising a first section 13 and a second section 15, each of said sections having a generally corrugated cross section rigid plastic foam interior 17 between two cover sheets 19 and 21 which are in intimate bonded contact with each corrugated surface profile of each foam interior 17. Sections 13 and 15 are adhesively fixed or bonded to each other along raised portions of the respective corrugations to define hollow passages 23 extending interiorly through the module 11. The edges of the module 11 are formed by cutting or other means each to define a vertical recess 25 having a cross-section generally corresponding to a one half cross section of one of the hollow passages 23. The crosssectional shape of these edge recesses may be adapted to suit various construction requirements such as, for example, in a manner to define an obtuse angle wall connection as shown in FIGURE 3 of the drawings. It should also be here noted that the module 11 as shown in FIGURE 1 may be strengthened structurally by insertion into the passages 23 of structural elements 39 at selected points, as shown in FIGURE 2 of the drawing, when additional load bearing capacity is required. A base plate 27 is shown extending along the underside of the module 11, which base plate may be of wood, metal or other suitable structural material. A cap strip 29 is shown positioned for arrangement along the top of the module 11. The cap strip, like the base plate, may be of wood, metal or other suitable structural material. Cleats 31 are attached to project vertically upward from the base plate 27 and downward from the cap strip 29. In assembling the wall, the cleats are inserted into the hollow passages 23 to secure the module 11 against lateral or longitudinal movement. The cleats may take a number of forms sc., continuous, intermittent or registerable with alternate passages 23 and may be of a variety of materials, such as wood blocks or, as shown in the drawings, extruded metal strips.

A typical spline assembly 33 to join the modules into a continuous wall comprises an elongate post member 35 and two key members 37, and is shown in cross sectional detail in FIGURE 2. FIGURE 2 also shows the manner in which a structural element 39 may be inserted into a hollow passage 23 of the module 11 to increase wall load bearing capacity when required. The spline assembly may also be in the form shown in FIGURE 3 where it desired to form an obtuse Wall angle and in the corner post form shown in FIGURE 4 of the drawings. In each case, it can be seen from the drawings that the key members 37 are close fitted into the recesses 25 at the panel module edges to lock the modules securely in alignment. To facilitate fitting key members 37 into the recesses 25, members 38, formed to fit the recesses and module edges, may be provided as shown in FIG- URES 2, 3 and 4. A half spline assembly with a single key member 37 is used to end a wall section as shown in FIGURE 1.

An alternative spline assembly is shown isometrically in FIGURE 5 and comprises a pair of complementary latch members 41 arranged each in adjoining vertical recess edges of a module 11 in combination with a latch port member 43. In the embodiment illustrated, each latch member 41 is a formed metal insert arranged to define a lining in a recess 25 and having inwardly extending returns 42. The returns 42 of two latch members at a module joint are lockably engaged by slots 45 on the latch port member 43, when said latch member is slid into position in the manner indicated in FIGURE 5 of the drawings.

Many adaptations and modifications of the structural system according to the present invention are possible, one of which is indicated in FIGURE 1 wherein a typical window installation is illustrated. To frame the window opening, a full height module 11 is cut to suit the dimensional requirements and a sill piece 47 and header piece 49 are installed as shown. It will be apparent that the sill piece and header piece correspond respectively to the cap strip 29 and the base plate 27.

Several assembly procedures are possible in constructing a wall system according to the present invention. One will be here described for illustrative purposes. Base plates 27 arranged to define a desired room shape are first nailed or otherwise attached to a subflooring construction. Cleats (if not already attached) are then added to the base plates. Modules 11, strengthened with structural elements 39 as required are then arranged on the cleats with spline assemblies being installed as required during the erection of the modules. If the spline assemblies are of wood or the like, the elongate post members 35 can be toe nailed into the base plates. Any necessary framing for doors, windows or other features is then installed. A cleated cap strip 29 is then installed and nailed or otherwise attached to the elongate post members, the structural element and corner posts.

Structural systems according to the present invention are insulative, lightweight and easily installed with a minimum of field work. The weight saving advantage of the system of this invention is outstanding in comparison with conventional building materials. The basic module may be a four by eight foot panel according to conventional standards, or any other dimensions desired. Foam panels are readily cut with conventional hand and power tools. Structures according to this invention may be additionally coated with a variety of finishing materials for protective and decorative effects. The hollow passages 23 may be advantageously utilized for building services such as electrical wiring and piping installations.

While, in the foregoing description, certain specific details and assembly steps have been set forth, together with certain suggested modifications, variations may be made in these without departing from the spirit of the present invention. The foregoing description has been given for clearness of understanding only and no unnecessary limitations should be understood therefrom.

What is claimed is:

1. A structural building wall system comprising, in combination;

(a) at least one insulative structural building module comprising a first section and a second section, each of said sections being substantially identical in physical characteristics and each comprising a rigid polyurethane foam plastic interior having a generally corrugated cross section and covering material bonded to the corrugated surfaces thereof, said first section being bonded adhesively to said second section continuously along raised portions of the respective corrugations in a manner to define a multiplicity of hollow passages extending interiorly through the panel, said module being arranged with the corrugations thereof vertically disposed, having first and second vertical edges formed to define respective vertical recesses each having a cross-section substantially corresponding to a one half cross-section of one of said multiplicity of hollow passages;

(b) a base plate arranged horizontally beneath the building panel and in coextensive contact with the underside thereof;

(c) a cap strip arranged horizontally above the building panel and in coextensive contact with the top thereof;

(d) a first multiplicity of vertically extending cleats attached to said base plate and each extending respectively into one of said multiplicity of hollow passages adjacent the underside of the panel;

(e) a second multiplicity of vertically extending cleats attached to said cap strip and each extending respectively into one of said multiplicity of hollow passages adjacent the top of the panel and (f) at least one vertical spline assembly extending vertically coextensive with the second vertical edge of said one panel, comprising means to eifect connection of said-second vertical edge of said one panel with a first vertical edge of another panel. 4

2. A structural building wall system according to claim 1 wherein said vertical spline assembly comprises an elon gate post member having a cross-section width at least as great as the overall outside surface to outside surface cross-section dimension of the panel and two key members extending vertically with and attached to said post member, each having a cross-section width and configuration to fit insertably into a vertical recess defined at a panel edge one of said two key members being received in the vertical recess in said second vertical edge of said one panel.

3. A structural building wall system according to claim 1 wherein said vertical spline assembly comprises an elongate first latch member arranged vertically in the vertical recess in said second edge of said one panel, a second latch member arranged vertically in a vertical recess at a first edge of another panel, the edges of said one panel and said another panel'being disposed in adjacent vertically aligned relation and an elongate latch port member engaging said first and said second latch members coextensively throughout the height of the panels.

References Cited by the Examiner UNITED STATES PATENTS Standau 52206 OTHER REFERENCES House and Home, page 142c, February 1959.

a FRANK L. ABBOTT, Primary Examiner.

JACOB L. NACKENOFF, HENRY C. SUTHERLAND,

Examiners.

RICHARD W. COOKE, JR., A. C. PERHAM,

Assistant Examiners. 

1. A STRUCTURAL BUILDING WALL SYSTEM COMPRISING, IN COMBINATION; (A) AT LEAST ONE INSULATIVE STRUCTURAL BUILDING MODULE COMPRISING A FIRST SECTION AND A SECOND SECTION, EACH OF SAID SECTIONS BEING SUBSTANTIALLY IDENTICA IN PHYSICAL CHARACTERISTICS AND EACH COMPRISING A RIGID POLYURETHANE FOAM PLASTIC INTERIOR HAVING A GENERALLY CORRUGATED CROSS SECTION AND COVERING MATERIAL BONDED TO THE CORRUGATED SURFACES THEREOF, SAID FIRST SECTION BEING BONDED ADHESIVELY TO SAID SECOND SECTION CONTINUOUSLY ALONG RAISED PORTIONS OF THE RESPECTIVE CORRUGATIONS IN A MANNER TO DEFINE A MULTIPLICITY OF HOLLOW PASSAGES EXTENDING INTERIORLY THROUGH THE PANEL, SAID MODULE BEING ARRANGED WITH THE CORRUGATIONS THEREOF VERTICALLY DISPOSED, HAVING FIRST AND SECOND VERTICAL EDGES FORMED TO DEFINE RESPECTIVE VERTICAL RECESSES EACH HAVING A CROSS-SECTION SUBSTANTIALLY CORRESPONDING TO A ONE HALF CROSS-SECTION OF ONE OF SAID MULTIPLICITY OF HOLLOW PASSAGES; (B) A BASE PLATE ARRANGED HORIZONTALLY BENEATH THE BUILDING PANEL AND IN COEXTENSIVE CONTACT WITH THE UNDERSIDE THEREOF; 